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Spike Systems CBG-100 System Manual

Automated motorized hydraulic traffic controller
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Automated Motorized Hydraulic Traffic Controller 
This manual describes the operational requirements of the CBG Hydraulic Traffic Control 
System as it is normally configured on site. 
CBG-100/120/140/160/180
SYSTEM MANUAL
Spike Systems 
3623 S. Seventh Street 
Phoenix, Arizona 85040 
Phone: (602) 243‐0291 
Fax: (602) 243‐0294 
 
 
 

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  • Page 1 CBG-100/120/140/160/180 SYSTEM MANUAL Automated Motorized Hydraulic Traffic Controller        Spike Systems  3623 S. Seventh Street  Phoenix, Arizona 85040  Phone: (602) 243‐0291  Fax: (602) 243‐0294  This manual describes the operational requirements of the CBG Hydraulic Traffic Control  System as it is normally configured on site. ...
  • Page 2    ...

  • Page 3: Table Of Contents

      Table of Contents Section 1 ‐ Pre‐Installation Planning and Considerations ......... 1   1.1 WARNINGS AND NOTICES ...................... 1   1.2 Product Model Numbers ...................... 1   1.3 Product Family Description and Specifications ............... 2   1.4 Right or Left Side Configuration ..................... 2   1.5 Spike Systems Crash Barrier Gate (CBG) Product Family Overview ...... 3   1.5.1 CBG‐100 As Installed and Dimensions for Installation Planning ........ 3   1.5.2 CBG‐120 As Installed and Dimensions for Installation Planning ........ 4   1.5.3 CBG‐140 As Installed and Dimensions for Installation Planning ........ 4   1.5.4 CBG‐160 As Installed and Dimensions for Installation Planning ........ 5   1.5.5 CBG‐180 As Installed and Dimensions for Installation Planning .
  • Page 4 4.1 Barrier Gate Manual Operation ................... 59  4.2 Barrier Gate Emergency Operation: Manual Gate Lowering ........60  4.3 Important Hydraulic Power Unit (Pump) Information ..........60  4.4 Barrier Gate Cable Maintenance Considerations ............62  4.5 On‐Going Maintenance Tasks ....................64  4.6 Maintenance Reference Information ................65  4.6.1 Hydraulic Control Unit Wiring .................... 6 5  Appendix A ‐ Warranty ......................71   Appendix B – Optional Inductive Loop Vehicle Detector Installation ....73   B.1 Inductive Loop Vehicle Detector (Saw Cut Control Loop) General Guidelines .. 73  B.2 Inductive Loop Vehicle Detector (Saw Cut Control Loop) Relay Connection..74  Appendix C ‐ Safety Warnings ................... 77   Figures Figure 1 ‐‐ CBG‐100 As Installed and Dimensions for Installation Planning ........... 3  Figure 2 ‐‐ CBG‐120 As Installed and Dimensions for Installation Planning ........... 4  Figure 3 ‐‐ CBG‐140 As Installed and Dimensions for Installation Planning ........... 4  Figure 4 ‐‐ CBG‐160 As Installed and Dimensions for Installation Planning ........... 5  Figure 5 ‐‐ CBG‐180 As Installed and Dimensions for Installation Planning ........... 5  Figure 6 ‐‐ Control and Non‐Control Cabinets Secured to Shipping Pallet ............. 7  Figure 7 – Inner Panel Removal from Control and Non‐Control Cabinets ............. 9  Figure 8 – Inductive Loop Vehicle Detector (Saw Cut Loop) Planning  ............ 10  Figure 9 – Temporary Placement of Control Cabinet to Mark Location of Saw Cut Beneath the Control  Cabinet ................................. 11  Figure 10 – Inductive Loop Vehicle Detector (Saw Cut Loop) Beneath Cabinet ...
  • Page 5 Figure 19 – CBG‐120 Placement of Fifth Ramp Segment ................ 19  Figure 20 – CBG‐120 Placement of Gate Into Ramp Segments to Verify Alignment  ........ 20  Figure 21 – CBG‐140 Placement of Fifth Ramp Segment ................ 21  Figure 22 – CBG‐140 Placement of Sixth Ramp Segment  ................ 21  Figure 23 – CBG‐140 Placement of Gate Into Ramp Segments to Verify Alignment  ........ 22  Figure 24 – CBG‐160 Placement of Fifth Ramp Segment ................ 23  Figure 25 – CBG‐160 Placement of Sixth Ramp Segment  ................ 23  Figure 26 – CBG‐160 Placement of Seventh Ramp Segment  ................ 24  Figure 27 – CBG‐160 Placement of Gate Into Ramp Segments to Verify Alignment  ........ 24  Figure 28 – CBG‐180 Placement of Fifth Ramp Segment ................ 25  Figure 29 – CBG‐180 Placement of Sixth Ramp Segment  ................ 26  Figure 30 – CBG‐180 Placement of Seventh Ramp Segment  ................ 26  Figure 31 – CBG‐180 Placement of Barrier Gate Into Ramp Segments to Verify Alignment  ...... 27  Figure 32 – Gate Hinge Installation, Control Cabinet ................... 28  Figure 33 – Detailed Gate Hinge Installation, Control Cabinet  .............. 29  Figure 34 – Gate Hinge Installation, Non‐Control Cabinet ................ 29  Figure 35 – Detailed Gate Hinge Installation, Non‐Control Cabinet  ............. 30  Figure 36 – Measurements to Ensure Proper Component Alignment ............ 31  Figure 37 – Hydraulic Cylinder Bleeder Valve Locations ................ 32 ...
  • Page 6 Figure 56 – Location of Traffic Control Mounting Adapter, Control Cabinet .......... 49  Figure 57 – Sealant Locations for Traffic Control Mounting Adapter, Control Cabinet ....... 50  Figure 58 – Traffic Control Signal Wiring ...................... 51  Figure 59 – Installation Location of Field Connection Barrier Operator  ............ 52  Figure 60 – Limit Switch Wiring (Usually Performed at Factory)  .............. 53  Figure 61 – Electronic Control Panel Components, Control Cabinet  ............ 54  Figure 62 – Electronic Control Panel Terminal Blocks, Control Cabinet  ............ 55  Figure 63 – 24 VDC Wiring Diagram, Control Cabinet .................. 56  Figure 64 – 110 VAC Wiring Diagram, Control Cabinet ................ 57  Figure 65 – Manual Operating Switch Location.................... 59  Figure 66 – Manual Gate Lowering in Case of Power Loss or Other Unusual Event ........ 60  Figure 67 – Barrier Gate Cable Access Panel Removal, Maintenance Only  .......... 62  Figure 68 – View Behind Gate Access Plate for Security Cable Removal and Replacement (Right Side  Shown)  ................................ 63  Figure 69 – View of Security Cable as Connected inside Barrier Gate (Left Side Shown) ...... 64  Figure 70 – Programmable Logic Controller  .................... 69  Figure 71 – Installation Location of Optional Inductive Vehicle Detection Module (Saw Cut Control),  Control Cabinet ............................ 74  Figure 72 – Typical Inductive Vehicle Detection Module (Saw Cut Control) .......... 75  Figure 73 – Wiring of Optional Inductive Vehicle Detection Module (Saw Cut Control), Control Cabinet .. 76  Spike Systems Electric Panel Schematics Drawing..................84...

  • Page 7: Section 1 - Pre-Installation Planning And Considerations

    Crash Barrier Gate Section 1 Section 1 ‐ Pre‐Installation Planning and Considerations 1.1 WARNINGS AND NOTICES The Spike Systems Hydraulic Crash Barrier Gate (CBG) is designed to regulate the flow of traffic  through a secure control point.  The CBG is also designed and manufactured to ensure personnel  safety when the equipment is operated properly and all safety precautions are strictly followed.  Persons responsible for the operation and field maintenance of the sytem should read this  manual carefully before attempting to operate the equipment or perform any service or  adjustment procedures.  The Warnings, Cautions, and Notes in this manual represent the following information:   A WARNING is an operation, procedure or condition that can cause injury or death.   A CAUTION is an operation, procedure or condition that can cause damage to the  equipment.   A NOTE provides helpful information.  The warnings and cautions that follow apply to all parts of this manual.  POTENTIALLY LIFE‐THREATENING HAZARDS MAY EXIST DURING EQUIPMENT  WARNING: OPERATION.  ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO OPERATE,  SERVICE OR MAKE ADJUSTMENTS TO THE HYDRAULIC TRAFFIC CONTROL  SYSTEM EQUIPMENT.  FOLLOW THE PRECAUTIONARY INSTRUCTIONS EXACTLY.  DO NOT TAKE  WARNING: SHORTCUTS.  DO NOT ASSUME THAT SOMEONE ELSE HAS ACTED ON YOUR  BEHALF.  IF ANY RULE OR PRECAUTION IS NOT CLEAR TO YOU, SEE YOUR  SUPERVISOR BEFORE USING THE MACHINE.  THIS UNIT CONTAINS A THERMALLY FUSED ELECTRIC MOTOR.  IF THE MOTOR  WARNING: STOPS, DO NOT ASSUME POWER IS NOT PRESENT.  UNEXPECTED MOTOR  START‐UP IS POSSIBLE AFTER THE PROTECTOR TRIPS.  DISCONNECT POWER  FROM CIRCUIT BEFORE PERFORMING ANY SERVICE TO THE MOTOR.  WHEN  POWER IS RECONNECTED, RESET PROTECTOR BEFORE ACTIVATING SYSTEM.  TO AVOID PERSONAL INJURY, BE AWARE THAT VOLTAGES ARE PRESENT IN THE  WARNING: HYDRAULIC TRAFFIC CONTROL SYSTEM.  VOLTAGES AS LOW AS 28 VOLTS CAN  CAUSE SERIOUS INJURY UNDER SOME CONDITIONS.  DO NOT BE MISLED BY THE  TERM LOW VOLTAGE.  Spike Systems assumes no liability for accident or injury incurred through improper use ...

  • Page 8: Product Family Description And Specifications

    Crash Barrier Gate Section 1 Model Number Guide  Spike CBG System  Clear Width    CBG‐100  10’    CBG‐120  12’    CBG‐140  14’    CBG‐160  16’    CBG‐180  18’    1.3 Product Family Description and Specifications   The CBG family is an automated hydraulic Crash Barrier Gate that is surface mounted. The  product line is designed primarily to prevent against unauthorized vehicles from either entering  or exiting a secured control point. Using hydraulic and solid state components, and with it’s  customizable control logic, it can easily be adapted to variety of uses, for example, revenue  control, rental car agency, security checkpoints, and others.    Operating Time:  Cycle to lower barrier 3 seconds  Cycle to raise barrier 3 seconds  Drive Configuration:  Automated hydraulic control power unit,  with tie‐rod Hydraulic Cylinders  Power Requirements:  1‐1/2 HP, 110V Single‐phase 18A. The unit can be built to meet any local power  requirement as to voltage, frequency and  phase ...

  • Page 9: Spike Systems Crash Barrier Gate (Cbg) Product Family Overview

    Crash Barrier Gate Section 1 drawings depict a left hand control. However, all installation steps are the same regardless of  orientation of the Barrier Gate and control.  Spike CBG systems ship to the installation location with all possible assembly and installation  steps pre‐performed by the factory. Each system is specifically configured to match and address  each sales order prior to shipment to the installation location.  The client is responsible for running necessary power to the installation location(s) with  separate conduit for low voltage controls. These controls often connect between the Control  Cabinet and a guard shack, but optionally can also attach to card readers and other optional  system inputs. Prior to commencing any installation steps, the installer should ensure that all  power and data connections have been properly installed, connected and configured.  1.5 Spike Systems Crash Barrier Gate (CBG) Product Family Overview 1.5.1 CBG‐100 As Installed and Dimensions for Installation Planning   Figure 1 -- CBG-100 As Installed and Dimensions for Installation Planning CBG‐100  Overall Width  Depth  Clear Width    156”  61”  10’ (120”) ...

  • Page 10: Cbg-120 As Installed And Dimensions For Installation Planning

    Crash Barrier Gate Section 1 1.5.2 CBG‐120 As Installed and Dimensions for Installation Planning     Figure 2 -- CBG-120 As Installed and Dimensions for Installation Planning CBG‐120  Overall Width  Depth  Clear Width    180”  61”  12’ (144”)  1.5.3 CBG‐140 As Installed and Dimensions for Installation Planning     Figure 3 -- CBG-140 As Installed and Dimensions for Installation Planning CBG‐140  Overall Width  Depth ...

  • Page 11: Cbg-160 As Installed And Dimensions For Installation Planning

    Crash Barrier Gate Section 1 1.5.4 CBG‐160 As Installed and Dimensions for Installation Planning     Figure 4 -- CBG-160 As Installed and Dimensions for Installation Planning CBG‐160  Overall Width  Depth  Clear Width    228”  61”  16’ (192”)  1.5.5 CBG‐180 As Installed and Dimensions for Installation Planning     Figure 5 -- CBG-180 As Installed and Dimensions for Installation Planning CBG‐180  Overall Width  Depth ...
  • Page 12 Crash Barrier Gate Section 1    ...

  • Page 13: Section 2 - Physical Installation

    Crash Barrier Gate Section 2 Section 2 – Physical Installation 2.1 Installation Preparation: System Unpacking All CBG systems are shipped to the installation site on custom designed pallets. An example is  shown below.  NOTE – Use a forklift or a sufficient number of laborers to lift the shipped pallets, the Control  Cabinet (shown on the left), the Non‐Control Cabinet (shown on the right), the Crash Barrier  Gate assembly (not pictured) and the pallet with ramp segments (not pictured). The use of  safety gloves is advised whenever lifting or handling CBG cabinets and components. Unbolt the  Control and Non‐Control Cabinets from the custom pallet using a 1/2“ wrench or ratcheting  socket.    Figure 6 -- Control and Non-Control Cabinets Secured to Shipping Pallet Tool Required  Tool Type  Tool Specification    ½” Wrench/Socket  To remove hardware  securing system  components to pallets    Safety Gloves   ...

  • Page 14: Crash Barrier Gate Component Weights

    Crash Barrier Gate System Section 2 2.2 Crash Barrier Gate Component Weights Component(s)  Component(s)  Weight (pounds)  Weights      Cabinets    Pallet with Control and Non‐ 1,030  Control Cabinet    Control Cabinet  545    Non‐Control Cabinet  445    Gate Arms    CBG‐100 Gate  200    CBG‐120 Gate  230    CBG‐140 Gate  260    CBG‐160 Gate  290    CBG‐180 Gate  350    Ramps    CBG‐100 Ramp Set ...

  • Page 15: Crash Barrier Gate (Cbg) System Installation

    Crash Barrier Gate System Section 2 2.3 Crash Barrier Gate (CBG) System Installation For ease of installation, it is recommended that the inner panels be removed from the Control  and Non‐Control Cabinet assemblies. The illustration below shows both inner panels exploded  from the assembly view of a CBG‐100.    Figure 7 – Inner Panel Removal from Control and Non-Control Cabinets   Tool Required  Tool Type  Tool Specification    Wrench/Socket  7/16”   ...

  • Page 16: Pre-Installation Considerations: Ensure Power And Data Conduits Are Properly In Place

    Crash Barrier Gate System Section 2 2.4 Pre‐Installation Considerations: Ensure Power and Data Conduits are Properly in Place Verify that the client‐supplied power conduit and any low voltage data connections, for example  to a guard shack for a control switch, are properly installed beneath where the Control Cabinet  will be secured.  Any other options to be installed, for example cabling for an electronic card reader, should have  the conduit run to the Control Cabinet prior to positioning the Control Cabinet in place. Once  the Control Cabinet has been anchored to the ground, it is very difficult to route any cabling into  the unit. (Drilling into the side of the unit is not recommended.) For this reason it is imperative  to ensure that all power and control data wiring be properly installed prior to installation.  Cabling for control data must always be run in a separate conduit from power.   2.5 Pre‐Installation Considerations: Optional Inductive Loop Vehicle Detector (Saw Cut Control Loop) The figure below depicts a CBG‐100 with an optional Inductive Loop Vehicle Detector or saw cut  control loop.  The rectangular loop should be cut and prepared prior to the system installation  process.   IMPORTANT NOTE ‐‐ the cut that leads from the loop to the area under the Control Cabinet  must be cut and extended under the base of the cabinet prior to any other installation steps.    Figure 8 – Inductive Loop Vehicle Detector (Saw Cut Loop) Planning  ...

  • Page 17: Saw Cut Inductive Loop Vehicle Detector As Preparation For Installation

    Crash Barrier Gate System Section 2   Tool Required  Tool Type  Tool Specification    Concrete Saw  3/16” Blade  depth set to 2”,   unless otherwise  specified  Inductive Loop   As supplied by factory  Vehicle Detector or Saw Cut Control  Module (option)   Broom or vacuum  To clean debris after  saw cut is performed    Pizza wheel, putty  To place wires into cut  knife or screwdriver  groves evenly  Inductive   Self‐leveling concrete  Sealant for  Loop Vehicle (Sikaflex SL or similar)  Detector or saw cut  loop   2.6 Saw Cut Inductive Loop Vehicle Detector as Preparation for Installation   If the installation is to include an Inductive Loop Vehicle Detector (saw cut control loop),  follow the instructions precisely as defined by the option’s manufacturer.

  • Page 18: Figure 10 - Inductive Loop Vehicle Detector (Saw Cut Loop) Beneath Cabinet

    Crash Barrier Gate System Section 2 Tool Required  Tool Type  Tool Specification    Forklift for unit  If a forklift is not  placement  available, use  sufficient labor to lift  and place the Control  Cabinet in position  Mark the path for saw cut underneath where cabinet will be installed. The location of where the  Inductive Loop Vehicle Detector wires should be routed out of the saw cut loop will be near  where power and other data conduit will be located under the Control Cabinet Once the path for the saw cut control wires has been established, remove the cabinet from its  temporary installation position to gain access to the ground beneath.    Saw cut the path under where Control Cabinet will be located.   The hidden line figure below shows the extension of the cut to the proper approximate location  beneath the Control Cabinet.      Figure 10 – Inductive Loop Vehicle Detector (Saw Cut Loop) Beneath Cabinet   Refer to Appendix B for further information on the Optional Inductive Vehicle Detector  installation. Note ‐‐ Ensure there is enough spare loop wire to reach the control panel, leaving  at least 12 inches of slack (beyond what is required to reach the control panel termination ...

  • Page 19: Permanent Control Cabinet Placement (Left Hand Configuration Shown)

    Crash Barrier Gate System Section 2     2.7 Permanent Control Cabinet Placement (Left Hand Configuration Shown)   Figure 11 – Placement of Control Cabinet   When the optional saw cut loop cut has been installed and sealed, and all power and data  condiut has been verified to be in proper location, place the Control Cabinet in its permanent  installation location.   It is adviseable to place two anchors in opposite corners of the Cabinet base to secure the  Control Cabinet at this time. This will ensure that the Cabinet does not shift while other  components are placed into installation position. Please refer to section 2.11 for information  on anchor installation.    Tool Required  Tool Type  Tool Specification    Forklift for unit  If a forklift is not  placement  available, use  sufficient labor to lift  and place the Control  Cabinet in position    Place the Non‐Control Cabinet in approximate location across from the Control Cabinet as  shown below. Do NOT anchor the Non‐Control Cabinet at this time.   Note that it will be necessary to leave ample room so the control arm Barrier Gate can be placed  in location after the ramps have been installed and before the Barrier Gate is attached to the  hinges and Hydraulic Cylinders.   ...

  • Page 20: Figure 12 - Placement Of Non-Control Cabinet

    Crash Barrier Gate System Section 2   Figure 12 – Placement of Non-Control Cabinet   Tool Required  Tool Type  Tool Specification    Forklift for unit  If a forklift is not  placement  available, use  sufficient labor to lift  and place the cabinets  in position   ...

  • Page 21: Ramp Installation Instructions

    Ramp Installation Steps  Spike Systems Model  Installation Data      CBG‐100 Gate  This Section    CBG‐120 Gate  This Section + Section 2.8.1    CBG‐140 Gate  This Section + Section 2.8.2    CBG‐160 Gate  This Section + Section 2.8.3    CBG‐180 Gate  This Section + Section 2.8.4    Starting with the Control Cabinet side first, place the first ramp in place as shown below. The  first ramp segment is numbered with a marker as number “1”.     Figure 13 – CBG-100 Placement of First Ramp Segment   There is a small punch on the ramp segment that indicates the side of the ramp of that  corresponds to traffic direction. It is essential that the ramps be placed correctly with the punch  oriented closest to where traffic will approach the Barrier Gate.  The first gate segment is placed  in position starting from the Control Cabinet side, and additional ramps will be placed  sequentially in the direction of the Non‐Control Cabinet. ...

  • Page 22: Figure 14 - Punch On Ramp Segment Indicating Traffic Flow Direction

    Crash Barrier Gate System Section 2   Figure 14 – Punch on Ramp Segment Indicating Traffic Flow Direction   NOTE ‐‐ DO NOT anchor or secure any ramp segments until all ramps have been placed,  the Non‐Control Cabinet has been placed in position, the Barrier Gate has been  positioned and secured to both cabinets and the proper travel of the Barrier Gate up  and down has been verified.   ...

  • Page 23: Figure 15 - Cbg-100 Placement Of Second Ramp Segment

    Crash Barrier Gate System Section 2   Place the second ramp segment in place as shown below. Do not anchor any ramp segments at  this time.      Figure 15 – CBG-100 Placement of Second Ramp Segment   Place the third ramp segment in place as shown below. Do not anchor any ramp segments at  this time.        Figure 16 – CBG-100 Placement of Third Ramp Segment    ...

  • Page 24: Figure 17 - Cbg-100 Placement Of Fourth Ramp Segment

    Place the forth ramp segment in place as shown below. Do not anchor any ramp segments at  this time.        Figure 17 – CBG-100 Placement of Fourth Ramp Segment   Lay the Barrier Gate in position within the ramps. Use pry bar or crowbar to adjust alignment of  each ramp so Barrier Gate travels into the opening without obstruction.    Figure 18 – CBG-100 Placement of Gate Into Ramp Segments to Verify Alignment   Tool Required  Tool Type  Tool Specification    Pry Bar or Crowbar  To adjust ramp  segment locations as  required for Barrier ...

  • Page 25: Additional Ramp Installation Instructions, Cbg-120

    Crash Barrier Gate System Section 2       If installing a CBG‐100, proceed to Section 2.9 “Barrier Gate Hinge Bolt Installation” after the  steps above have been performed.  Otherwise, refer to the specific subsection for additional installation steps for the product  being installed.    Ramp Installation Steps  Spike Systems Model  Installation Data      CBG‐120 Gate  Section 2.8.1    CBG‐140 Gate  Section 2.8.2    CBG‐160 Gate  Section 2.8.3    CBG‐180 Gate  Section 2.8.4    2.8.1 Additional Ramp Installation Instructions, CBG‐120 Continuing from the CBG‐100 ramp installation process (Section 2.8), for the CBG‐120 place the  fifth ramp segment in place as shown below. DO NOT anchor or secure any ramp until all ramps  have been placed, the Non‐Control Cabinet has been placed in position and the proper travel of  the Barrier Gate up and down has been verified.    Figure 19 – CBG-120 Placement of Fifth Ramp Segment  ...

  • Page 26: Additional Ramp Installation Instructions, Cbg-140

    Crash Barrier Gate System Section 2   Lay the Barrier Gate in position within the ramps. Use a pry bar or crowbar to adjust alignment  of each ramp so the Barrier Gate travels into the ramp opening without obstruction.    Figure 20 – CBG-120 Placement of Gate Into Ramp Segments to Verify Alignment   Tool Required  Tool Type  Tool Specification    Pry Bar or Crowbar  To adjust ramp  segment locations as  required for Barrier  Gate clearance    If installing a CBG‐120, proceed to Section 2.9 “Barrier Gate Hinge Bolt Installation” after the  steps above have been performed.  2.8.2 Additional Ramp Installation Instructions, CBG‐140 Continuing from the CBG‐100 ramp installation process (Section 2.8), for the CBG‐140 place the  fifth ramp segment in place as shown below. DO NOT anchor or secure any ramp until all ramps  have been placed, the Non‐Control Cabinet has been placed in position and the proper travel of  the Barrier Gate up and down has been verified. ...

  • Page 27: Figure 21 - Cbg-140 Placement Of Fifth Ramp Segment

    Crash Barrier Gate System Section 2   Figure 21 – CBG-140 Placement of Fifth Ramp Segment   Place the sixth ramp segment in place as shown below. Do not anchor any ramp segments at  this time.    Figure 22 – CBG-140 Placement of Sixth Ramp Segment  ...

  • Page 28: Additional Ramp Installation Instructions, Cbg-160

    Crash Barrier Gate System Section 2 Lay the Barrier Gate in position within the ramps. Use a pry bar or crowbar to adjust alignment  of each ramp so the Barrier Gate travels into the ramp opening without obstruction.    Figure 23 – CBG-140 Placement of Gate Into Ramp Segments to Verify Alignment   Tool Required  Tool Type  Tool Specification    Pry Bar or Crowbar  To adjust ramp  segment locations as  required for Barrier  Gate clearance    If installing a CBG‐140, proceed to Section 2.9 “Barrier Gate Hinge Bolt Installation” after the  steps above have been performed.    2.8.3 Additional Ramp Installation Instructions, CBG‐160   Continuing from the CBG‐100 ramp installation process (Section 2.8), for the CBG‐160 place the  fifth ramp segment in place as shown below. DO NOT anchor or secure any ramp until all ramps  have been placed, the Non‐Control Cabinet has been placed in position and the proper travel of  the Barrier Gate up and down has been verified. ...

  • Page 29: Figure 24 - Cbg-160 Placement Of Fifth Ramp Segment

    Crash Barrier Gate System Section 2   Figure 24 – CBG-160 Placement of Fifth Ramp Segment   Place the sixth ramp segment in place as shown below. Do not anchor any ramp segments at  this time.      Figure 25 – CBG-160 Placement of Sixth Ramp Segment  ...

  • Page 30: Figure 26 - Cbg-160 Placement Of Seventh Ramp Segment

    Crash Barrier Gate System Section 2   Place the seventh ramp segment in place as shown below. Do not anchor any ramp segments at  this time.    Figure 26 – CBG-160 Placement of Seventh Ramp Segment Lay the Barrier Gate in position within the ramps. Use a pry bar or crowbar to adjust alignment  of each ramp so the Barrier Gate travels into the ramp opening without obstruction.    Figure 27 – CBG-160 Placement of Gate Into Ramp Segments to Verify Alignment...

  • Page 31: Additional Ramp Installation Instructions, Cbg-180

    Crash Barrier Gate System Section 2     Tool Required  Tool Type  Tool Specification    Pry Bar or Crowbar  To adjust ramp  segment locations as  required for Barrier  Gate clearance    If installing a CBG‐160, proceed to Section 2.9 “Barrier Gate Hinge Bolt Installation” after the  steps above have been performed.      2.8.4 Additional Ramp Installation Instructions, CBG‐180   Continuing from the CBG‐100 ramp installation process (Section 2.8), for the CBG‐180 place the  fifth ramp segment in place as shown below. DO NOT anchor or secure any ramp until all ramps  have been placed, the Non‐Control Cabinet has been placed in position and the proper travel of  the Barrier Gate up and down has been verified.      Figure 28 – CBG-180 Placement of Fifth Ramp Segment  ...

  • Page 32: Figure 29 - Cbg-180 Placement Of Sixth Ramp Segment

    Crash Barrier Gate System Section 2 Place the sixth ramp segment in place as shown below. Do not anchor any ramp segments at  this time.    Figure 29 – CBG-180 Placement of Sixth Ramp Segment   Place the seventh ramp segment in place as shown below. Do not anchor any ramp segments at  this time.    Figure 30 – CBG-180 Placement of Seventh Ramp Segment  ...

  • Page 33: Figure 31 - Cbg-180 Placement Of Barrier Gate Into Ramp Segments To Verify Alignment

    Crash Barrier Gate System Section 2   Lay the Barrier Gate in position within the ramps. Use a pry bar or crowbar to adjust alignment  of each ramp so the Barrier Gate travels into the ramp opening without obstruction.    Figure 31 – CBG-180 Placement of Barrier Gate Into Ramp Segments to Verify Alignment   Tool Required  Tool Type  Tool Specification    Pry Bar or Crowbar  To adjust ramp  segment locations as  required for Barrier  Gate clearance    If installing a CBG‐180, proceed to Section 2.9 “Barrier Gate Hinge Bolt Installation” after the  steps above have been performed.     ...

  • Page 34: Barrier Gate Hinge Bolt Installation

    Crash Barrier Gate System Section 2   2.9 Barrier Gate Hinge Bolt Installation Remove the bolts, washers, bearings and nuts from both the Control Cabinet and Non‐ Control Cabinet Barrier Gate hinges using a ¾” wrench.   Place the Non‐Cabinet in final installation position, so the Barrier Gate fits properly into the hinge locations in both the Control and Non‐Control Cabinet. NOTE ‐‐ ensure that ramp segments are properly aligned for clear and unobstructed travel of the Barrier Gate up and down. It may be necessary to make small adjustments to the position of any component to ensure proper alignment and movement of the Barrier Gate prior to final anchoring.  Install Control Cabinet hinge bolts to Barrier Gate using ¾” wrench, as shown below.    Figure 32 – Gate Hinge Installation, Control Cabinet Tool Required  Tool Type  Tool Specification    Wrench/Socket  ¾”   ...

  • Page 35: Figure 33 - Detailed Gate Hinge Installation, Control Cabinet

    Crash Barrier Gate System Section 2   Figure 33 – Detailed Gate Hinge Installation, Control Cabinet Install Non‐Control Cabinet hinge bolts to Barrier Gate using ¾” wrench, as shown below.    Figure 34 – Gate Hinge Installation, Non-Control Cabinet   Tool Required  Tool Type  Tool Specification    Wrench/Socket  ¾”   ...

  • Page 36: Figure 35 - Detailed Gate Hinge Installation, Non-Control Cabinet

    Crash Barrier Gate System Section 2   Figure 35 – Detailed Gate Hinge Installation, Non-Control Cabinet   Important – When the hinge bolts have been secured to both the Control and Non‐Control  Cabinets, verify the clear and unobstructed travel of the Barrier Gate up and down, in and out of  the ramps. Adjust any ramp segments with a crowbar or pry bar, if necessary.  When the Barrier Gate is in position and secured in both Gate Hinges, it is advisable to verify the  proper alignment of the Barrier Gate with a measuring tape. As shown in the figure below, the  distance from the Barrier Gate (in the down position) to the end of both cabinet bases should be  exactly three inches. Adjust the position of the Non‐Control Barrier Gate as needed to ensure  that all four measurements are three inches, and that the Barrier Gate enters and exits the  recesses of the ramp segments without any obstruction.    Tool Required  Tool Type  Tool Specification    Tape Measure  To verify 3” distance  from the Barrier Gate  (in down position) to  the end of the base of  both Cabinets.  ...

  • Page 37: Figure 36 - Measurements To Ensure Proper Component Alignment

    Crash Barrier Gate System Section 2 Figure 36 – Measurements to Ensure Proper Component Alignment...

  • Page 38: Hydraulic Cylinder Bolt Installation

    Crash Barrier Gate System Section 2   2.10 Hydraulic Cylinder Bolt Installation NOTE – In order to install the Hydraulic Cylinders to the Barrier Gate (while the Barrier Gate is in  the down position), it will be necessary to open the upper bleeder valve on the Hydraulic  Cylinder in order to pull the shaft outward for connection to the Barrier Gate. This process may  cause air to enter the system. Ensure that the bleeder valve is closed after the shaft has been  extended and secured to the Barrier Gate. After the hydraulic hoses have been installed to the  Non‐Control Cabinet Hydraulic Cylinder, it will be necessary to bleed the system as documented  later.    Figure 37 – Hydraulic Cylinder Bleeder Valve Locations Tool Required  Tool Type  Tool Specification    Wrench  3/8”  ...

  • Page 39: Figure 38 - Hydraulic Cylinder Bolt Installation, Non-Control Cabinet

    Crash Barrier Gate System Section 2 Install Hydraulic Cylinder bolts on the Non‐Control Cabinet side using ¾” wrench as shown  below.    Figure 38 – Hydraulic Cylinder Bolt Installation, Non-Control Cabinet     Figure 39 – Detail View - Hydraulic Cylinder Bolt Installation, Non-Control Cabinet   Tool Required  Tool Type  Tool Specification    Wrench/Socket  ¾”     ...

  • Page 40: Figure 40 - Hydraulic Cylinder Bolt Installation, Control Cabinet

    Crash Barrier Gate System Section 2 Install Hydraulic Cylinder bolts on the Control Cabinet side using ¾” wrench as shown below.    Figure 40 – Hydraulic Cylinder Bolt Installation, Control Cabinet     Figure 41 – Detailed View - Hydraulic Cylinder Bolt Installation Control Cabinet   Tool Required  Tool Type  Tool Specification    Wrench/Socket  ¾” ...

  • Page 41: Installation Of Concrete Anchors

    Crash Barrier Gate System Section 2 2.11 Installation of Concrete Anchors   2.11.1 System View Prior to Anchor Installation   Before concrete anchors are installed, the CBG system should resemble the figure below.    Figure 42 – System View Prior to Anchor Installation   To ensure that the gate is properly positioned between the Control and Non‐Control Cabinets, it  is advisable to measure the distance from the gate (in the down position) to the bottom of the  Cabinet base plates in four locations. All four measurements should be exactly the same as  shown in the following figure.  Tool Required  Tool Type  Tool Specification    Tape Measure  To ensure the distance  from the lowered gate  to the base of the  Cabinets is the same  in 4 locations. ...

  • Page 42: Figure 43 - General Measuring Guideline To Ensure Component Alignment

    Crash Barrier Gate System Section 2     Figure 43 – General Measuring Guideline to Ensure Component Alignment   Specifically, the gate to base plate measurement should be 3” in all four locations. If this is NOT  the case, make minor adjustments to the Non‐Control Cabinet position and re‐measure.    Figure 44 – Specific Measuring Guideline to Ensure Component Alignment   When the Barrier Gate has been secured to the hinges on both the Control and Non‐Control  Cabinets, and to the Hydraulic Cylinders, verify the proper travel of the Barrier Gate in both the ...

  • Page 43: Figure 45 - Titen Head Anchor Bolt

    Crash Barrier Gate System Section 2 up and down directions. When settling into the down position, the Barrier Gate should clear the  ramp modules without obstruction. If necessary, use a pry bar to adjust the location of any ramp  module that prevents clear travel of the Barrier Gate into the ramp recess. It is essential that the  travel of the Barrier Gate be verified prior to the installation of any anchor bolts. When Gate  travel has been confirmed, insert anchor bolts in Control Cabinet, all ramp segments, and the  Non‐Control Cabinet. Ensure that anchors are installed in all locations of all components.      Figure 45 – Titen Head Anchor Bolt...
  • Page 44 Crash Barrier Gate System Section 2     Tool Required  Tool Type  Tool Specification    Hammer Drill or    similar for concrete  drilling    Concrete Bit  5/8” masonry bit.  Drill  a minimum depth of  4”    Air Compressor or  To remove dust and  similar  debris from drilling    Wrench/Socket  15/16”    Concrete Anchors  5/8” x 4” Titen Head  Screw Anchor Zinc,  Part Number  THD62400H   ...

  • Page 45: Section 3 - Hydraulic, Electrical, And Control Installation

    Crash Barrier Gate Section 3 Section 3 – Hydraulic, Electrical, and Control Installation 3.1 Hydraulic Hose Installation The factory pre‐installs a set of hydraulic hoses to the Hydraulic Cylinder in the Control Cabinet. After the Barrier Gate ramps have been installed, adjusted and anchored, the two hydraulic hoses are threaded from the Control Cabinet through the ramps to the Non‐ Control Cabinet. Once routed through the ramps, the two hoses are attached to the Hydraulic Cylinder in the Non‐Control Cabinet. The two hoses that are to be threaded through the ramp are coiled up in the Control Cabinet as shown below. Start this portion of the installation by uncoiling the hydraulic hoses and extending them fully to ensure that there are no kinks or bends in the hoses. Figure 46 – Hydraulic Hose Location, As Shipped, Inside Control Cabinet To connect the hydraulic hoses to the Hydraulic Cylinder in the Non‐Control Cabinet, extend a fish tape through the recess of the ramps from the Non‐Control Cabinet side to the Control Cabinet side. Carefully attach the hydraulic hoses to the fish tape using electrical or other strong tape. From the Non‐Control Cabinet side, carefully pull the fish tape and hydraulic hoses through the ramp assemblies as shown below. When the hoses have been fully extended, remove the fish tape from the hydraulic hoses.

  • Page 46: Figure 47 - Two Hydraulic Hoses Routed Through Ramp Gates To Non-Control Cabinet

    Crash Barrier Gate System Section 3 Figure 47 – Two Hydraulic Hoses Routed Through Ramp Gates to Non-Control Cabinet Tool Required Tool Type Tool Specification Fish Tape 15’ minimum for CBG‐100, up to 25’ for CBG‐180 Tape (Electric or Electric or other other) strong tape to attach 2 hydraulic hoses to fish tape When the hoses have been extended through the ramps to the Non‐Control Cabinet, carefully route the hoses to the location of the Hydraulic Cylinder ensuring that there are no kinks or sharp bends in the hydraulic hoses.

  • Page 47: Hydraulic System Bleeding

    Crash Barrier Gate System Section 3 Attach the hydraulic hoses to the Hydraulic Cylinder in two locations as shown below. NOTE – Both hydraulic hoses are color coded to correspond to color codes on the hydraulic cylinder. Ensure that the RED coded hose is attached to the RED coded location on the hydraulic cylinder in the Non‐Control Cabinet. In a similar fashion, ensure that the GREEN coded hose is attached to the GREEN coded location on the hydraulic cylinder in the Non‐ Control Cabinet. Figure 48 – Hydraulic Hose Connection, Non-Control Cabinet Tool Required Tool Type Tool Specification Wrench 9/16” to attach Hydraulic Hoses, 2 locations 3.2 Hydraulic System Bleeding NOTE – When the Hydraulic Cylinder has been attached to the Barrier Gate, and the two  hydraulic hoses have been attached to the cylinder on the Non‐Control Cabinet, it is necessary  to bleed hydraulic system to ensure air has been evacuated from the lines and the system.  ...
  • Page 48 Crash Barrier Gate System Section 3 The Spike Systems CBG family removes air from the hydraulic lines through normal use of the  system. However, after installing the hydraulic hoses and cylinders, it is often advisable to  manually bleed or purge air from the system. To do this, place a 3/8” drain hose on the upper  bleeder valve in the Non‐Control Cabinet, place the other end of the bleeder hose in a waste  container, open the bleeder valve and operate the Barrier Gate up and down (manually) until air  no longer comes through the bleeder tube. To avoid performing this step manually, which  requires the lifting and lowering of the Barrier Gate, hydraulic system bleeding can be  performed after the installation is complete by using AC power to lift and lower the Barrier  Gate.   WARNING ‐‐ Use extreme caution to avoid injury if using AC power to raise and lower the  Barrier Gate when performing hydraulic system bleeding.   When air has been purged from the hydraulic system, retighten the bleeder valves, remove the  drain hose and clean any hydraulic fluid that may have dripped inside either Cabinet.  Tool Required  Tool Type  Tool Specification    Wrench  3/8”    3/8” Rubber Hose   To attach to the  bleeder valve for  bleeding air from  hydraulic system    Disposable container   To capture hydraulic  fluid that may be  released while  bleeding    Rag  To clean area inside  cabinets of any  hydraulic fluid ...

  • Page 49: Verify Proper Alignment Of Upper Limit Switch Within Control Cabinet

    Crash Barrier Gate System Section 3 3.3 Verify Proper Alignment of Upper Limit Switch within Control Cabinet Verify that the Barrier Gate, when elevated, makes proper contact with upper limit switch in the Control Cabinet. (Note that the Non‐Control Cabinet does not have limit switches.) It may be necessary to make a slight adjustment to the upper control limit switch location by bending the bracket slightly to ensure proper contact with the Barrier Gate arm in the raised position. Figure 49 – View of Upper and Lower Limit Switches, Control Cabinet...

  • Page 50: Figure 51 - Location Of Lower Limit Switch, Control Cabinet, Reference Only

    Crash Barrier Gate System Section 3 Figure 50 – Location of Upper Limit Switch, Control Cabinet Figure 51 – Location of Lower Limit Switch, Control Cabinet, Reference Only...

  • Page 51: Replace Inside Panels For Control And Non-Control Cabinets

    Crash Barrier Gate System Section 3 3.4 Replace Inside Panels for Control and Non‐Control Cabinets At this time, replace the inner panels of both the Control and Non‐Control Cabinets as shown in the figure below. Figure 52 – Replacement of Inner Panels Control and Non-Control Cabinets Tool Required Tool Type Tool Specification Wrench/Socket 7/16 “...

  • Page 52: Reflective Tape Installation On Barrier Gate

    Crash Barrier Gate System Section 3 3.5 Reflective Tape Installation on Barrier Gate With a lint‐free cloth, carefully clean the area of the Barrier Gate where the reflective adhesive tape will be applied. Starting from the Control Cabinet side, peal off the backing of the adhesive tape and secure the tape to the Barrier Gate squarely and evenly. Ensure that no air bubbles are present as the tape is applied. If needed, trim any excess reflective tape on the Non‐Control Cabinet side of the Barrier Gate. Figure 53 – Reflective Tape Application, Crash Barrier Gate Tool Required Tool Type Tool Specification Lint Free Cloth To clean and prepare surface where tape to be applied Razor or Scissors To trim safety tape, if required Reflective Tape Provided...

  • Page 53: Ac Power Connection

    Crash Barrier Gate System Section 3 3.6 AC Power Connection The client‐supplied power is to be connected to the 4‐gang junction box via flexible conduit. The flexible conduit and power wires are to be routed through the bottom of the junction box in the location shown in the photo below. Local code may require that a licensed electrical contractor perform this step. NOTE – The Switch on the 4‐gang junction box, when switched to the ON position, allows power to flow to the Spike system from the AC power source. WARNING ‐‐ When servicing the system, this switch should be placed in the OFF position and the power going to the junction box should be shut off at the breaker box. When AC power is OFF at this switch and breaker box, voltages may still be present within the Spike System Control Box. Use caution. Figure 54 – AC Power Junction Box Inside Control Cabinet...

  • Page 54: Figure 55 - Location Of Flexible Conduit Installation To Ac Junction Box, Control Cabinet

    Crash Barrier Gate System Section 3 Tool Required Tool Type Tool Specification Flexible Conduit To connect power conduit stub‐up to 4 gang box Conduit Fitting To connect flexible conduit to client‐ installed rigid conduit Flat Blade Screw To open junction box Driver and terminate power cables Wire Strippers To make electrical connection (Licensed contractor) The figure below shows a typical routing of the flexible conduit that will provide power to the CBG system. A locally licensed electrical contractor should perform electrical power connection to the Spike System. Figure 55 – Location of Flexible Conduit Installation to AC Junction Box, Control Cabinet...

  • Page 55: Traffic Control Signal Mounting

    Crash Barrier Gate System Section 3 3.7 Traffic Control Signal Mounting Figure 56 – Location of Traffic Control Mounting Adapter, Control Cabinet Install the traffic control light fixture as shown in the figure above. This step is often performed at the factory. However, field installers should ensure that the flange is sealed with UV resistant silicon or other method to ensure that moisture does not enter the Control Cabinet. Thread the wires for the signal through the pole and flange for attachment at the control panel. Tool Required Tool Type Tool Specification Channel Locks Large size to secure mounting hardware Silicon UV‐Resistant To ensure tight, Sealant/Caulk water‐resistant coupling...

  • Page 56: Figure 57 - Sealant Locations For Traffic Control Mounting Adapter, Control Cabinet

    Crash Barrier Gate System Section 3 Figure 57 – Sealant Locations for Traffic Control Mounting Adapter, Control Cabinet...

  • Page 57: Figure 58 - Traffic Control Signal Wiring

    Crash Barrier Gate System Section 3 3.7.1 Wiring for Traffic Control Signal As shown in the figure below, the wiring for the traffic control signal terminates on TB2 (terminal block on right side). The yellow light signal connects to terminal 9, the red light signal wire connects to terminal 10, and the common wire connects to terminal 47. Figure 58 – Traffic Control Signal Wiring Tool Required Tool Type Tool Specification Screw Driver Flat, Small Wire Strippers If required for cable connection...

  • Page 58: Wiring For Remote Operating Switch (Guard Shack, Typically)

    Crash Barrier Gate System Section 3 3.8 Wiring for Remote Operating Switch (Guard Shack, Typically) As indicated in the figure below, a field connection barrier operated switch or control is wired to TB2. The Common wire is attached to terminal 4, the Open wire is attached to terminal 5, and the Close wire is attached to terminal 6. Figure 59 – Installation Location of Field Connection Barrier Operator Tool Required Tool Type Tool Specification Screw Driver Flat, Small Wire Strippers If required for cable connection...

  • Page 59: Figure 60 - Limit Switch Wiring (Usually Performed At Factory)

    Crash Barrier Gate System Section 3 Figure 60 – Limit Switch Wiring (Usually Performed at Factory)  ...

  • Page 60: Installation Electrical Reference Information

    Crash Barrier Gate System Section 3 3.9 Installation Electrical Reference Information Figure 61 – Electronic Control Panel Components, Control Cabinet...

  • Page 61: Figure 62 - Electronic Control Panel Terminal Blocks, Control Cabinet

    Crash Barrier Gate System Section 3   Figure 62 – Electronic Control Panel Terminal Blocks, Control Cabinet...

  • Page 62: Figure 63 - 24 Vdc Wiring Diagram, Control Cabinet

    Crash Barrier Gate System Section 3     Figure 63 – 24 VDC Wiring Diagram, Control Cabinet...

  • Page 63: Figure 64 - 110 Vac Wiring Diagram, Control Cabinet

    Crash Barrier Gate System Section 3 Figure 64 – 110 VAC Wiring Diagram, Control Cabinet...
  • Page 64 Crash Barrier Gate System Section 3...

  • Page 65: Section 4 - System Operation And Maintenance

    Crash Barrier Gate Section 4 Section 4 ‐ System Operation and Maintenance 4.1 Barrier Gate Manual Operation When all electrical connections have been made for the system, including all options, apply power to the system via the AC circuit breaker. Next, ensure that the power switch on the 4‐gang electrical junction box is placed in the ON position. Before testing the remote access devices (for example from a control shack), it is recommended that the system operation be tested using the manual operating switch, located on the outside of the electronic control compartment within the Control Cabinet. This switch is identified in the figure below. When system functionality has been verified from the manual operating switch, verify all other system controls. Figure 65 – Manual Operating Switch Location...

  • Page 66: Barrier Gate Emergency Operation: Manual Gate Lowering

    Crash Barrier Gate System Section 4 4.2 Barrier Gate Emergency Operation: Manual Gate Lowering If it ever becomes necessary to lower a Barrier Gate manually, for example in the event of power loss or other unusual situation, open the locking door on the Control Cabinet to gain access to the system hydraulic pump. As pictured below, turning the pump release valve in the clockwise direction will allow the gate to go down manually. Ensure that this valve is turned in the opposite direction (counter‐ clockwise) once system operation has been restored. Figure 66 – Manual Gate Lowering in Case of Power Loss or Other Unusual Event 4.3 Important Hydraulic Power Unit (Pump) Information Observations and Recommendations When connecting AC current, please observe the indicated rotation of the electric motor. Running the motor in the opposite direction of the indication will result in...
  • Page 67 Crash Barrier Gate System Section 4 shaft seal damage. All electric connections should be done according to local standards. Failure to comply with local standards and use of non‐certified components may result in injury. All hydraulic connections should be made, and the proper fluid should be present in the reservoir before, running the Hydraulic pump. Seal Kits and Components To obtain a seal kit, the model number and serial number of the powerpack is needed. Most parts are available separately, however the pump is only replaced in whole and separate trust‐plates or loose shafts cannot be obtained. In order to ensure the quality and performance of our product, all Hydraulic pumps are tested for performance at the factory. Connections Hoses and fittings connected to the pump should be clean and free of any burs, oxidation and carbon deposits. The hydraulic connections must be of adequate pressure rating, and should be inspected on a regular basis to avoid leakage or possible bursting due to high pressure. The size of the hydraulic connections must be determined with the oil flow of the hydraulic pump in mind (1000 PSI) to avoid back‐pressure in the system. This could create unwanted heat buildup. The fluid level in the reservoir should be monitored at regular intervals. A fluid level below the intake strainer will cause damage to the pump due to cavitations of the pump. The hydraulic pump is designed to stand vertically. Adjustments Since the hydraulic pump has a fixed displacement pump installed, oil flow is constant and determined by the speed of the electric motor. Therefore, the pump flow cannot be adjusted. The adjustment for the pressure relief valve will adjust pressure only. It will not increase pump flow. The relief valve is set to a pressure specified when the hydraulic pump was tested. The specified pressure applies to the specific system in which it is installed. The setting can be changed in the field and should be as close as possible to the maximum working pressure of the system. The standard pressure relief valve protects the pump; it should only be adjusted if the pressure reaches an unwanted high level. It is an emergency valve only. It should not be blocked off or turned in completely to avoid bursting of components. Adjustments are made by first removing the cap nut and loosening the lock nut. A clockwise rotation of the adjustment stem increases the pressure and a counter‐ clockwise rotation decreases pressure. The lock nut should be tightened after adjustment, and the cap nut should be re‐installed to avoid changing the setting by vibration and to avoid hydraulic fluid leakage. Please contact the factory if you have any questions or concerns relating to your hydraulic pump.

  • Page 68: Barrier Gate Cable Maintenance Considerations

    Crash Barrier Gate System Section 4 4.4 Barrier Gate Cable Maintenance Considerations When new systems are shipped to an installation site, the security cable is already in place inside the Barrier Gate, and the access plates are secured. For a new installation, it is not necessary to modify the security cable in any way. From a maintenance perspective, if a vehicle contacts the Barrier Gate and bends or distorts the Barrier Gate, replacement of the Barrier Gate is required. When this occurs, the security cable can be removed from the damaged Barrier Gate and installed within the replacement Barrier Gate. To remove a security cable from a damaged Barrier Gate, remove both square access plates (right and left) from the Barrier Gate assembly using a ½” wrench or socket. It may be necessary to use a flat blade screwdriver to pry the cable loop off of the circular internal support on both sides. Pull the cable through the damaged Barrier Gate from either side. To install a security cable inside a Spike Systems Gate, ensure that both access plates (left and  right) have been removed from the replacement Barrier Gate using a ½” wrench or socket. From  either side of the Barrier Gate, thread the cable through the Barrier Gate and place the loop of  the cable over the circular support on each side of the Barrier Gate. Once the cable is placed  over both circular supports, replace the right and left access plates.  Figure 67 – Barrier Gate Cable Access Panel Removal, Maintenance Only...

  • Page 69: Figure 68 - View Behind Gate Access Plate For Security Cable Removal And Replacement

    Crash Barrier Gate System Section 4 Tool Required Tool Type Tool Specification Wrench/Socket ½” to open remove safety cable cover plate Flat blade screw To pry cable loop driver from circular internal support Figure 68 – View Behind Gate Access Plate for Security Cable Removal and Replacement (Right Side Shown)

  • Page 70: On-Going Maintenance Tasks

    Crash Barrier Gate System Section 4 Figure 69 – View of Security Cable as Connected inside Barrier Gate (Left Side Shown)   4.5 On‐Going Maintenance Tasks BEFORE YOU USE A MATERIAL, REFER TO THE WARNING: MANUFACTURES’ MATERIAL SAFETY DATA SHEETS FOR SAFETY INFORMATION. SOME MATERIALS CAN BE DANGEROUS.

  • Page 71: Maintenance Reference Information

    Crash Barrier Gate System Section 4 4.6 Maintenance Reference Information 4.6.1 Hydraulic Control Unit Wiring Gate Access Controller I/O Terminal Address Description Voltage Notes Main Power Terminal Block 110 VAC Switched Power Terminal Block 110 VAC PLC Fuse Block 110 VAC Fuse size 1A PLC Output Fuse Block 110 VAC Fuse size 8A *** Neutral 110 VAC Pump Neutral...
  • Page 72 Crash Barrier Gate System Section 4 Gate Access Controller Output Terminal Address Description Voltage Notes Gate arm controller signal common No power from controller Q 0.7 Gate arm controller signal open dry No power from contact controller Q 1.0 Gate arm controller signal closed dry No power from contact controller...
  • Page 73 Crash Barrier Gate System Section 4 Terminal Board 2 From Siemens 1L loop 2L 7 0.0 Jumper 1 to 2 Jumper 3 to 4 SIRIUS 3R, 5L3 Q 0.7 Q 1.0 Q 0.0 Q 0.1 Q 0.3 Q 0.4 Q 0.2 Q 0.2 to SIRIUS 3R, A1 N-PLC Siemens N N-CR-A2...
  • Page 74 Crash Barrier Gate System Section 4 Inductive Loop Vehicle Detector Model LMA-1150-HV AC Line 120V AC Neutral Output Relay, Common Output Relay, Normally Open (Closes for DETECT) Loop Input Loop Input Output Relay, Normally Closed (Opens for DETECT) SIRIUS 3R (Relay) Siemens PLC Q 0.2 TB2-N-CR 1 L1 TB1-32...

  • Page 75: Figure 70 - Programmable Logic Controller

    Crash Barrier Gate System Section 4 Figure 70 – Programmable Logic Controller...
  • Page 76 Crash Barrier Gate System Section 4  ...

  • Page 77: Appendix A - Warranty

    Crash Barrier Gate System Appendix A Appendix A ‐ Warranty   SPIKE SYSTEMS, Inc., hereinafter referred to as Spike Systems, warrants it’s products  will be free from defects in workmanship and materials when installed, and used and  serviced as intended, for a period of one (1) year from date of original invoice.    CBG – Automated Hydraulic Crash Barrier Gate  Model Numbers – CBG‐100/‐120/‐140/‐160/‐180    Spike Systems agrees to repair or replace, at Spike Systems choice and expense, any  defective product at no additional charge.  This warranty extends only to the original  Purchaser.  It is not transferable to anyone who subsequently purchases, leases, or  otherwise obtains the Product from the original Purchaser.  This warranty does not  cover road surfaces, concrete or other structures, underground equipment or fittings,  repair labor, travel time, mileage, shipping, or freight charges, taxes, preventive  maintenance and inspections or the replacement of items that are by nature,  consumable.  No allowance for damages to equipment due to power fluctuations will  be considered; a clean power supply is the responsibility of the customer.  The  warranty is voided if any modifications, changes or additions to the equipment are  performed without written approval from Spike Systems.  In addition, this warranty  may be voided or further limited if required and or recommended repairs,  maintenance, or inspections are not carried out as specified, or if defect is due to  normal wear, misuse, abuse, accident, installation not in accordance with instructions  or applicable codes, unauthorized repair or incidents commonly referred to as Acts of  God.  Spike Systems retains the right to the final determination as to the cause of any  defect.  Except for the warranties set forth herein, Spike Systems disclaims all other  warranties, expressed or implied or statutory, including but not limited to the implied  warranties of merchantability, or fitness or suitability for any particular purpose,  activity or location.    Spike Systems will in no event be liable for any loss of business, profits, data or use, or  any direct, indirect, incidental or consequential damages resulting from any such  defect in materials or workmanship.  You agree that repair, replacement or refund, as  applicable, under this warranty described herein is your sole and exclusive remedy  with respect to any breach of the Spike Systems Limited warranty set forth herein. ...
  • Page 78 Crash Barrier Gate System Appendix A  ...

  • Page 79: Appendix B - Optional Inductive Loop Vehicle Detector Installation

    Crash Barrier Gate System Appendix B   Appendix B – Optional Inductive Loop Vehicle Detector Installation   For Specific Installation Instructions, Refer to Manufacturer’s Documentation  Cut the rectangle for Inductive Loop Vehicle Detector per manufacturer’s instructions and  ensure that the loop makes proper connection to the cut that runs under the Control Cabinet.  Ensure there is enough spare loop wire to reach the control panel, leaving at least 12 inches of  slack (beyond what is required to reach the control panel termination point) as a service loop.  Specific installation instructions can be found at the following Internet sites.  http://www.editraffic.com/ http://www.renoae.com B.1 Inductive Loop Vehicle Detector (Saw Cut Control Loop) General Guidelines Use the table below as a guideline for cutting the saw cut loop to correspond with the Spike  Systems CBG system being installed.    Saw Cut  Spike Systems Model  Saw Cut Rectangle Dimensions  Guideline      CBG‐100 Gate (10’)  2’ x 6’    CBG‐120 Gate (12’)  2’ x 6’    CBG‐140 Gate (14’)  2 ‘ x 6’ or custom size (Note 1)    CBG‐160 Gate (16’)  2 ‘ x 6’ or custom size (Note 1)    CBG‐180 Gate (18’)  2 ‘ x 6’ or custom size (Note 1)     Note 1 – All systems that include an Inductive Loop Vehicle Detector option ship with ...

  • Page 80: Inductive Loop Vehicle Detector (Saw Cut Control Loop) Relay Connection

    Crash Barrier Gate System Appendix B   When the wires are in place, seal the grove that runs beneath where the Control Cabinet will be  installed. Once all wires are in place, seal the cut groves with self‐leveling concrete or Sikaflex SL  Self‐Leveling Sealant or similar.    B.2 Inductive Loop Vehicle Detector (Saw Cut Control Loop) Relay Connection The figure below indicates the location where the Inductive Vehicle Loop Detection module is to be attached within the electronic control panel. The pins on this device are keyed so that there is only one correct way to plug in the module. Attach the loop wires to pins 24 and 25 on the Terminal Block marked TB1. Note – TB1 is the vertical terminal on the left in the figure below, and TB2 is on the right. Figure 71 – Installation Location of Optional Inductive Vehicle Detection Module (Saw Cut Control), Control Cabinet...

  • Page 81: Figure 72 - Typical Inductive Vehicle Detection Module (Saw Cut Control)

    Crash Barrier Gate System Appendix B Figure 72 – Typical Inductive Vehicle Detection Module (Saw Cut Control)

  • Page 82: Control Cabinet

    Crash Barrier Gate System Appendix B Figure 73 – Wiring of Optional Inductive Vehicle Detection Module (Saw Cut Control), Control Cabinet Tool Required Tool Type Tool Specification Screw Driver Flat, Small Wire Strippers If required for cable connection...

  • Page 83: Appendix C - Safety Warnings

    Crash Barrier Gate System Appendix B Appendix C ‐ General Safety The following safety instructions, and any/all applicable local, city, state and fereral  regulations/laws/codes are to be observed for the installation and operation of this  barricade.  1.  Locate the barrier away from pedestrian traffic and restrict all pedestrian traffic  away from the barricade.  2.  Locate the barricade far enough from the street so an exiting or entering  vehicle  can clear the barricade completely while waiting to pull into or out  into traffic.  3.  The closing and opening actions must be observed. The mounting of operating  switches or signals outside the field of direct view is not permiossible; there  must be a line of site between the barrier and the control switches.  4.  It is forbidden for person or goods to be anywhere within the swing zone or the  barrier while in operation. Severe damage. injury or loss of life may occor.  5.  Provide adequate nighttime illumination of the unit and signs warning of it's  presence.   ...
  • Page 84 CREATED: 1/9/2017 4/28/2017 LAST MODIFIED: 03-13 47-2 03-13 35-1 03-9 03-9 TB2 2 2-L1 1-2, 2-3 Littelfuse 0217001.HXP 5x20mm Siemens S7-1200 CPU 1214C AC/DC/Relay 6ES72141BG400XB0 S7-1200 CPU 1214C AC/DC/Relay TB2 3 Siemens 6ES72141BG400XB0 3-1L Littelfuse 0312008.HXP 6.3x32mm...

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